U.S. patent number 8,852,442 [Application Number 13/031,724] was granted by the patent office on 2014-10-07 for solid chemical dissolver and methods.
This patent grant is currently assigned to Ashland Licensing and Intellectual Property LLC, Delaware Capital Formation, Inc.. The grantee listed for this patent is George S. Grabow, Richard E. Haas, Matthew S. Hayas, Donald A. Holt. Invention is credited to George S. Grabow, Richard E. Haas, Matthew S. Hayas, Donald A. Holt.
United States Patent |
8,852,442 |
Hayas , et al. |
October 7, 2014 |
Solid chemical dissolver and methods
Abstract
A solid chemical feed unit dissolver has an upper feed unit
chamber with an inwardly tapering sealing surface at its lower end
and against which a lowermost feed unit seals, retaining the upper
chamber in a dry condition, preventing wetting and caking of solid
chemical feed units behind the dissolving and sealed off face of
the solid chemical feed unit. A solid chemical feed unit magazine
is slotted to permit gentle feeding of a plurality of solid
chemical feed units therein and a cover-defined sight slot permits
guiding and visual observation of remaining solid chemical feed
units in the magazine. The magazine preferably, but not
necessarily, defines the tapering sealing surface. Distinctly
shaped solid chemical feed units are disclosed. The dissolver can
handle large solid chemical feed unit loads up to one hundred
pounds or more and in a small footprint stable configuration.
Methods are disclosed.
Inventors: |
Hayas; Matthew S. (Cincinnati,
OH), Grabow; George S. (Powell, OH), Holt; Donald A.
(Whitby, CA), Haas; Richard E. (Milford, OH) |
Applicant: |
Name |
City |
State |
Country |
Type |
Hayas; Matthew S.
Grabow; George S.
Holt; Donald A.
Haas; Richard E. |
Cincinnati
Powell
Whitby
Milford |
OH
OH
N/A
OH |
US
US
CA
US |
|
|
Assignee: |
Delaware Capital Formation,
Inc. (Wilmington, DE)
Ashland Licensing and Intellectual Property LLC (Dublin,
OH)
|
Family
ID: |
44063707 |
Appl.
No.: |
13/031,724 |
Filed: |
February 22, 2011 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20120111962 A1 |
May 10, 2012 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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61339702 |
Mar 8, 2010 |
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Current U.S.
Class: |
210/749; 210/679;
221/197; 210/753; 221/174; 210/764; 134/6 |
Current CPC
Class: |
B01F
1/0033 (20130101) |
Current International
Class: |
B01D
15/00 (20060101); C02F 1/76 (20060101); B08B
7/00 (20060101); C02F 1/68 (20060101); B23Q
7/00 (20060101); B65H 1/00 (20060101) |
Field of
Search: |
;422/261,292,300,311,902,905 ;210/679,749,753,764
;134/6,22.13,22.16-22.17,22.19
;221/30,66-67,69,135,154,174,186,191,197 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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0259038 |
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Mar 1988 |
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EP |
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2306301 |
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May 1997 |
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GB |
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5168678 |
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Jul 1993 |
|
JP |
|
9173271 |
|
Jul 1997 |
|
JP |
|
9276202 |
|
Oct 1997 |
|
JP |
|
Primary Examiner: Chorbaji; Monzer R
Attorney, Agent or Firm: Wood, Herron & Evans, LLP
Parent Case Text
PRIORITY CLAIM
Benefit of the filing date, Mar. 8, 2010 of provisional patent
application Ser. No. 61/339,702 entitled SOLID CHEMICAL DISSOLVER
AND METHODS is claimed, and that application, in its entirety, is
expressly incorporated herein as if fully set out herein.
Claims
What is claimed is:
1. A method of dissolving a solid chemical feed unit in a solid
chemical feed unit dissolver having a solid chemical feed unit
chamber including an inwardly tapered surface proximate one end
thereof, including the steps of: introducing a solid chemical feed
unit in said chamber; creating a seal at a seal location between
said solid chemical feed unit and said tapered surface when an edge
of said solid chemical feed unit engages said surface; and spraying
a diluent onto a face of said solid chemical feed unit defined by
said edge, and including the further steps of advancing said solid
chemical feed unit toward said seal location while spraying said
face and dissolving said solid chemical feed unit, and while
retaining a seal between said solid chemical feed unit and said
tapered surface.
2. A process as in claim 1 further comprising the steps of: forming
a chemical solution from chemical at said face; and feeding said
chemical solution to a process stream.
3. A method for loading a solid chemical feed unit magazine in a
dissolver with a plurality of solid chemical feed units including
the steps of: introducing a solid chemical feed unit to a mouth of
a feed unit magazine; lowering successive ones of said solid
chemical feed units into said magazine; manipulating said solid
chemical feed units as they are loaded into an upper end of said
magazine by engaging said solid chemical units from outside said
magazine and through elongated slots disposed through said
magazine, and including the step of sealing a lowermost solid
chemical feed unit on an inwardly tapered surface of said magazine
when said lowermost solid chemical feed unit is lowered in said
magazine.
4. A process for producing a chemical solution formed from a solid
chemical to a process stream and comprising the steps of: feeding a
solid chemical feed unit having a forward face toward a dissolving
position; spraying a diluent pattern onto said face to dissolve
solid chemical at said face into a chemical solution; sealing said
solid chemical feed unit at an edge thereof around said face
against a surface, and preventing said pattern of diluent from
contact with said solid chemical feed unit behind said face by
engaging said edge of solid chemical around said face with said
surface; and transporting said chemical solution to a process
stream.
5. Process as in claim 4 wherein said sealing step includes
engaging said feed unit face edge on an inwardly tapering portion
of said surface.
6. A method as in claim 4 including feeding at least one solid
chemical feed unit toward said seal location as a solid chemical
feed unit face is dissolved.
7. A method as in claim 4 wherein said spraying is one of
continuous or intermittent.
Description
FIELD OF THE INVENTION
This invention relates to apparatus and methods for dissolving
chemicals from a solid form to produce a chemical solution. More
particularly, this invention relates to chemical dissolvers and
methods for producing chemical solutions for water or process
treatment from solid form chemicals.
BACKGROUND OF THE INVENTION
It is known to provide concentrated chemical solution for
introduction into liquid systems or processes for a variety of
purposes. For example, chemical concentrates, including mixtures of
different chemistries, are diluted to provide solutions for water
treatment and prevention of scale and deposit accretion and buildup
in tanks, boilers and cooling towers and in both open and closed
water systems, for industrial cleaning, for detergent production in
dishwashing systems and washing machines, for other cleaning and
sanitizing purposes, and for continual and periodic cleaning and
maintenance functions in a variety of applications.
Typically, a "dissolver" for dissolving or diluting a chemical is
used to receive a chemical concentrate, dissolve or dilute it, and
introduce the resulting solution to a system for treatment.
Specific disclosures of such prior apparatus and processes are
found, for example, in U.S. Pat. Nos. 2,371,720; 3,383,178;
3,595,438; 4,858,449; 4,964,185; 5,137,694; 6,441,073; 6,418,958;
6,820,661; in United States Patent Publication Nos. US2007/0269894
and US2010/0025338. Each of these is expressly incorporated herein
by reference and is a part hereof as if fully set out herein.
Copies of these are attached and are a part hereof.
Moreover, it will be appreciated that systems for producing a
concentrated chemical solution and for delivering that solution to
a system for use are typically designed for specific applications
due to the parameters of the system to be treated; all the way from
washing machines on one hand to closed loop water tower and
processes or building cooling systems on the other. Volumes,
pressures, temperatures, water chemistries, chemical solutions
required and many other parameters require significantly different
dissolving and delivery systems.
Another consideration in this field is the state or form of the
concentrated chemical used to form the treatment solution.
Concentrated chemicals can be provided in either a concentrated
liquid form or in a "solid" form. The term "solid" is herein used
to differentiate or distinguish from other forms of chemical such
as granules, flakes, beads, free flowing aggregates, particulates,
powder and liquid. The terms "solid" and "solid chemical feed unit"
as used herein are thus intended to refer to a monolithic mass in a
freestanding, structural shape which may be formed by any suitable
process including but not limited to compression, casting, molding
and other processes. When dissolving a chemical in solid form, it
is typical to spray a pattern of water onto the face of the solid
chemical.
Comparisons of liquid to solid concentrated chemicals are set out
in United States Patent Pub No. US2010/0025338, incorporated herein
by reference.
When considering use of chemicals in solid form such as solid
chemical feed units, particularly in the treatment of larger water
systems such as heating and cooling systems, relatively larger
amounts of concentrated chemical are required as compared to
smaller volume systems. Regardless of the size of the solid
chemical feed unit system, the feeding and dissolving process must
be consistent so the chemical solution produced by the dissolving
process is accurate and consistent.
Potentially interfering with these considerations is the nature of
the interface of the solid chemical feed unit being dissolved by a
water spray. While it is important to consistently dissolve
chemical from the solid feed unit at a forward surface of that
unit, it is also desirable to maintain chemical behind that surface
as dry as possible to prevent such wetting and caking as would
prevent consistent presentation of chemical at a location where the
water spray most effectively and uniformly dissolves the chemical.
Said in another way, if chemical in a solid feed unit behind the
interface of the forward surface and the water spray becomes wet or
cakes, feeding or movement of the solid chemical feed unit toward
the spray interface can be adversely affected, as well as the
surface of the solid chemical receiving the spray pattern. This can
result in stoppages, in inconsistent solution production and in
production of widely varying solution content adversely affecting
the efficiency and viability of the treatment desired.
In another aspect of solid chemical feed unit dissolving, it is
desirable that operator time and attendance at the dissolver be
reduced, even while the dissolver must be capable of producing
large amounts of chemical solution for large volume applications.
This requires operable disposition of significant numbers of solid
chemical feed units in the dissolver. While a plurality of such
solid chemical feed units might be stacked, such as a small
plurality of such solid chemical feed units in a much lower
capacity dissolver (like four solid chemical feed units provided in
a gallon-sized bucket), it is desired to provide apparatus and
processes for handling much larger amounts of solid chemical feed
units for much larger applications without the frequent operator
attention required for gallon-sized solid chemical feed unit fills
in such larger units.
It is also desirable to provide solid chemical feed unit dissolvers
facilitating use of multiple solid chemical feed units without
damage from dropping solid chemical feed units one onto another,
and without feeding or consistency issues arising from wetting or
caking. For example, in some applications, it may be desirable to
accommodate fills of about fifty to two hundred pounds or so of
total solid chemical feed unit weight where large volume systems
are to be serviced. And it is desired to do so within a small
dissolver footprint, but in a stable application.
Finally, it is desirable to provide the capability of observing the
feed units in the dissolver as an indication of current status and
the need to replenish the feed units for consistent treatment.
Typical small capacity dissolvers do not provide such observation
capacity.
SUMMARY OF THE INVENTION
To these ends, the invention contemplates an improved solid
chemical feed unit dissolver and solid chemical feed units combined
to facilitate multiple solid chemical feed unit filling, provide
high capacity dissolver operation, prevent undesirable feed unit
caking and wetting, provide visual feed unit status and provide
consistent sustainable chemical dissolving and solution for system
treatment, all in a small footprint and from a stable
dissolver.
A preferred embodiment of the invention contemplates a magazine
sized and shaped to handle, preferably, a plurality of solid
chemical feed units, in one form comprising disc-shaped feed units
stacked vertically in the upper chamber of the magazine. A tapered
sealing surface, smaller in diameter than the lower face of a
disc-shaped feed unit, is preferably an integral part of the lower
end of the magazine. The periphery of the lowermost feed unit rests
on this surface, sealing the upstream chamber of the magazine from
a spray directed upwardly through a screen and against the lower
face of the lowermost feed unit to dissolve the solid chemical into
a solution flowing downwardly and collected in a reservoir.
As the lower face of the feed unit is dissolved, the feed init
progressively feeds, downwardly toward the plane defined by the
lower dissolving face thereof and its seal contact with the tapered
surface.
Thus, as the solid chemical is dissolved by the spray at this lower
face, that feed unit, and those above, move progressively
downwardly, yet the upper chamber above the plane where the
dissolving action occurs is sealed by the advancing chemical feed
unit so the upper chamber and feed units therein are retained in a
relatively drier area and do not mat, clog or otherwise adversely
affect the accurate and consistent dissolving of the chemical at
the lower face of the lowermost feed unit.
The magazine is provided with access slots to facilitate gentle
handling of the feed units which are loaded into the magazine, and
with visual access therein to permit an operator to determine the
load status of the magazine.
These and other advantages and modifications of the invention will
become readily apparent from the following written description and
from the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustrative cross-sectional view showing a dissolver
with feed unit magazine mounted thereon and showing the lower end
of the magazine where the inwardly tapering surface forms a seal
with the lower edge of the lowermost solid chemical feed unit;
FIG. 2 is an isometric view of a dissolver and magazine as in FIG.
1 wherein selected components are shown in transparent format for
clarity and explanation;
FIG. 3 is a perspective view of a dissolver and magazine of FIG. 1,
illustrating an uncovered magazine, filled with solid chemical feed
units;
FIG. 4 is an elevational view of the dissolver and covered magazine
of FIG. 1, with solid chemical feed units visible through a
magazine slot and cover sight window;
FIG. 5 is a top plan view of a dissolver and magazine; and
FIG. 6 is a schematic flowchart showing flow of regulated water
from the regulator to the serially connected second and first
valves to the spray nozzle, and also illustrating diagrammatically
the overflow tank and the solution reservoir (depicted in two
places), as well as the solid chemical feed unit, tapered sealing
surface and screen.
DETAILED DESCRIPTION OF THE INVENTION
Preferably as used herein, the term "dissolver" includes a solid
chemical feed unit dissolving apparatus and an associated
operatively mounted solid chemical feed unit magazine or guide for
holding and introducing successive solid chemical feed units
sequentially to a dissolving location or station in the
dissolver.
As illustrated in the drawings, preferred solid chemical feed units
useful in the invention are in the form of a cylinder or disc 10
having a forward face 12 defined by a circular edge 14. Disc 10 has
predetermined height and is preferably, but not necessarily, from
six to nine inches in diameter, about one to six inches in height
and preferably three inches high. Preferably, the forward face 12
is about 20 inches to 110 square inches in surface area.
Preferably, a single solid chemical feed unit weighs in the range
of eight to ten pounds. These parameters are illustrative only;
other sizes, areas and weights could be used.
One embodiment of the invention comprises a unique solid chemical
feed unit magazine 16 in operable cooperation as part of a
dissolver apparatus 18 wherein the magazine 16 has a slight
inwardly tapered surface or constriction 20 at a lower magazine end
22, just upstream or above a first screen 24. As noted, a solid
chemical feed unit 10 is preferably, but not exclusively,
cylindrical in shape, with a lower circular face surface 12 defined
by an edge 14 engaging the tapered surface 20 of the magazine 16
and sealing off upper chamber areas 26 of the magazine above the
seal 28 produced by the engagement of the lower feed unit edge 14
with the tapered surface 20.
Alternately, the tapered surface 20 may be operatively disposed in
the dissolver 18 at a seal location downstream of the magazine 16,
while providing a seal against moisture intrusion into the magazine
16 and above the face surface 12 of a feed unit 10 being
dissolved.
The upper first screen 24 is disposed in the magazine 16 proximate
the so-formed seal 28 and just below the lower face 12 of the
forward or lowermost solid chemical feed unit 10. The first screen
24 is of any suitable construction and preferably of stainless
steel wire in No. 2 mesh, i.e. one-half inch mesh. An upwardly
directed nozzle 30 is disposed below the screen 24. The nozzle 30
sprays a consistent and preferably uniform water pattern up through
the screen onto the lower circular face 12 of the solid chemical
feed unit 10, which is thus dissolved. As the solid chemical feed
unit 10 is so dissolved, dissolved chemical drops toward and
through the first screen 24 onto a collection funnel 32 or tapered
collecting surface thereof, yet all the while its advancing lower
face 12 at its circular edge 14 seals against the tapered surface
20, preventing wetting and caking of the solid chemical feed unit
or units 10 above the dissolving face 12. The solid chemical feed
unit 10 and successive solid chemical feed units descend in the
magazine 16 toward the tapered surface 20 and seal as the nozzle 30
continues to spray, maintaining both the seal 28 and the
presentation of a feed unit surface for dissolving by the nozzle 30
spray. The seal 28 is maintained whether the nozzle spray 30
produces continuously or intermittently.
As the face 12 of the solid chemical feed unit 10 is sprayed and
dissolved by the water, diluted chemical solution falls past the
nozzle onto a secondary, lower screen 34 at the bottom of funnel 32
for catching any lumps or pieces of undissolved chemicals falling
through the first screen 24 and which are collected and optionally
presented to waste. The lower screen 34 is preferably an integral
part or floor of the collection funnel 32 with a plurality of
one-quarter inch holes therein, whereby pieces of undissolved
chemical are captured in the floor and can be further
dissolved.
Thus, it will be appreciated that the magazine 16 defines an upper
feed unit chamber 26 for accepting a plurality of solid chemical
feed units 10 in tandem and for feeding each unit 10 serially
toward the tapering surface 20, forming a seal 28 with the edge 14
of the lowermost feed unit.
In another aspect of the invention, the magazine 16 defines two
elongated slots 36, 38 (FIG. 3) on opposite sides thereof.
Cylindrically-shaped solid chemical feed units 10 are manually
lowered within the magazine 16 and from the top by physical support
facilitated by the slots 36, 38, until the feed units 10 are
settled on the seal 28 or on the proceeding feed unit 10. A guide
cover 40 is placed on the last or uppermost feed unit 10 and
follows the units 10 downwardly as they are successively dissolved.
If the last unit in the magazine is fully dissolved, the guide
cover 40 deflects any spray from the nozzle 30 from entering the
magazine chamber 26 through the screen; it too sealing or
contacting the tapering seal surface 20.
A magazine cover 42 may be disposed over the magazine 16. This
cover 42 is preferably provided with an elongated sight window 44
with measuring scale aligned with one of said slots 36, 38 and
through which the feed units 10 therein can be viewed and measured
as an indication of solid chemical feed unit status and any need to
load more solid chemical feed units 10. It is thus easy for an
operator to assure continued operation of a treatment process by
visual observation.
Just below the tapered surface 20 of the magazine, 16 a circular
groove 46 in a surface of either the magazine 16 or other dissolver
parts accommodates, supports or positions the periphery of the
circular screen 24 noted above. The further tapered surface below
the screen in the form of a collection funnel 32 funnels chemical
solution downwardly to a collection area or reservoir 48 within the
dissolver 18 wherein one or more floats 50, 52 are disposed to
control water flow through line 55 to the nozzle 30 based on the
fill condition of a solution reservoir 48. Primary chemical
solution is directed to a solution reservoir 48 in which a float 52
activates a first valve 54 when the reservoir 48 is filled,
shutting off water to the nozzle 30. If that reservoir 48 has
overflowed into an overflow tank 56 despite the condition of the
first valve 54 and its float 52, a second float 50 in the overflow
tank 56 shuts a second valve 58, serially connected to the first
valve 54 (through conduit 57) from upstream thereof, as a failsafe
to shut off water from water inlet 59, pressure regulator 59a and
conduit 61, to the first valve 54, line 55 and nozzle 30 and to
stop nozzle 30 spray onto a feed unit 10. The supply of water to
the serially-connected valves 54, 58 and nozzle 30 is pressure
regulated to produce a consistent spray from the nozzle 30.
A pick-up tube 60 transfers chemical solution to an outlet pump 62
from the solution reservoir 58 for transport to a water system or
other process stream.
Also, it will be appreciated that the invention is useful in
multiple applications where available water pressures might vary
significantly from one application to the other and in the
approximate range of 25 to 100 psi and more likely 25-40 psi.
According to the invention, the water supply nozzle 30 is regulated
to about 25 psi (regulator 59a) and at this pressure, the nozzle 30
delivers water diluent in a spray pattern to the face of the solid
chemical feed unit at a rate of about 0.5 gallons per minute to
produce a chemical solution at about 0.5% to about 1.0%
concentration.
Preferably, and to provide consistent chemical solution by
presenting a continually uniform solid chemical feed unit face 12
and surface area defined at the forward face, each solid chemical
feed unit 10 has a shape such that surface area of the solid
chemical feed unit is positioned at a constant distance from the
nozzle 30 at the first screen 24. Provision of a uniform water
pattern, emanating from a nozzle 30 at a uniform distance from the
face of the operative solid chemical feed unit, and at a uniform
low pressure facilitates a consistent, accurate and constant
solution and treatment process.
It will also be appreciated that the dissolver 18 provides a very
high capacity solid chemical feed unit dissolving process but in a
relatively small footprint. Essentially, the dissolver unit 18 at
its lower end is about 24 inches wide by 28 inches long and about
one foot tall, or alternately, it could be other sizes, such as 18
inches wide and about 22 inches long. The housing 66 forms
preferably integral both reservoir 48 and overflow tanks 56 of
about one quart capacity each, and an additional containment tank
68 beyond these two tanks to accommodate an unexpected spill or
malfunction. The magazine has an upper loading end 70, about five
feet from the bottom of the dissolver housing 66, and is about
thirteen inches in diameter, with cover 42. The lower end of the
magazine is secured to the dissolver housing 66 so it does not
separate if the entire apparatus is tipped. Since the lower end of
the magazine 16 is disposed within the housing 66, the center of
gravity of the unity is relatively low and the dissolver is stable.
For example, magazine 16 may be supported by an integral seat 72 of
housing 66, and other portions of the housing 66 and may be
otherwise suitably fastened to the housing.
It will thus be appreciated that the dissolver 18 is partially
defined by a housing 66 or body which usefully comprises a molded
housing 66 of any suitable material defining a solution reservoir
48, an overflow tank 56, a containment tank 68, a seat 72 for a
magazine and such conduits, valves 54, 58 nozzle 30 and the like to
perform the dissolving function. The reservoir 48 and overflow tank
56 may be an integrally formed portion of the dissolver body 66. As
will be appreciated, the magazine 16 is removably but securely
seated on the dissolver 18 as shown in the drawings. The tapered
sealing surface 20 and screen 24 could be formed in the dissolver
18, below a magazine 16, if desired, as opposed to the preferred
disposition as part of the magazine 16.
In an alternate embodiment, the solid chemical feed units 10 may be
provided in other shapes than cylinders or discs. For example, a
disc shape with a sector removed, a unit in the form of a
multiple-sided shape of curved or straight lines, or a variety of
other feed unit shapes could be used. Consequently, the tapering
seal surface 20 may also be provided in similar and cooperating
configurations to produce the seal 28 with the solid chemical feed
unit 10 discussed herein and to prevent moisture transport or
migration beyond a spray-receiving dissolving face 12 of such a
feed unit.
The parameters of a uniform pattern consistent with the shape of
the solid chemical feed unit face 12, uniform distance from spray
nozzle 30 to that face, and uniform water pressure are all
preferably provided and retained.
These embodiments facilitate treatment of a variety of process
streams from solid chemical feed units.
From the foregoing, it will be appreciated that the invention
provides a solid form chemical dissolver having a unique high
capacity magazine and solid chemical feed units and which prevents
dissolving process obstruction from wetting or caking of subsequent
solid chemical feed units as well as provides consistent chemical
dissolving, either continuously or intermittently, and resulting
accurate solutions for system treatments. These benefits are
attained in addition to such improved apparatus and methods as a
result from a dissolver of small footprint, providing high capacity
in a yet stable unit with accurate solution production and
decreased operator time and attention.
A variety of solid chemicals provided in solid chemical feed units
can be used with this invention. These include, by way of example
only, and without limitation: phosphonate; tolytriazole; molybdate;
polymers; caustics; sulfite and nitrate.
These and other advantages and modifications will become readily
apparent to those of ordinary skill in the art and without
departing from the scope of this invention and applicant intends to
be bound only by the claims appended hereto.
* * * * *